Method of and apparatus for burning internal combustion engine exhaust gases

ABSTRACT

A method of and apparatus for substantially completely burning the unburned &#39;&#39;&#39;&#39;heavy ends&#39;&#39;&#39;&#39; of the hydrocarbon gases emanating from internal combustion engines comprising a tubular member disposed axially within the engine exhaust manifold in spacedapart relation with the manifold walls, and one or more brushlike members disposed within the tubular member including a helically twisted core of relatively stiff wire having a multitude of relatively fine wire bristles possessing high heat retention and corrosion resistance projecting generally radially in random array from the core, and means for supporting the brush-like member within the tubular member with the distal ends of the bristles spaced from, but in close proximity to, the tubular walls.

United States Patent Beller et al.

METHOD OF AND APPARATUS FOR BURNING INTERNAL COMBUSTION ENGINE EXHAUST GASES Inventors: Herbert R. Beller, Mount Clemens,

Mich.; George R. Onufer, Tulsa, Okla.

Russell, Burdsall & Ward, Inc., Port Chester, N.Y. by said Onufer Filed: Apr. 14, 1972 Appl. No.: 243,986

Assignee:

References Cited UNITED STATES PATENTS Behrens Roselund Primary ExaminerDouglas Hart Attorney, Agent, or Firm-Burton and Parker [57] ABSTRACT A method of and apparatus for substantially completely burning the unburned heavy ends" of the hydrocarbon gases emanating from internal combustion engines comprising a tubular member disposed axially within the engine exhaust manifold in spaced-apart relation with the manifold walls, and one or more brushlike members disposed within the tubular member including a helically twisted core of relatively stiff wire having a multitude of relatively fine wire bristles possessing high heat retention and corrosion resistance projecting generally radially in random array from the core, and means for supporting the brush-like member within the tubular member with the distal ends of the bristles spaced from, but in close proximity to, the tubular walls.

7 Claims, 4 Drawing Figures Ill! 1 METHOD OF AND APPARATUS FOR BURNING INTERNAL COMBUSTION ENGINE EXHAUST GASES BACKGROUND OF THE INVENTION With the present day concern over ecology, a great deal of blame has been placed upon the internal combustion engine as a source of air contamination, and strenuous efforts have recently been directed toward solution of the air pollution problem. The prime source of pollution from internal combustion engines is the discharge into the atmosphere of the unburned heavy ends of the hydrocarbons due to incomplete combustion within the engine. Of the attempts heretofore made to solve this pollution problem, none have proved entirely satisfactory, most have been comparatively expensive, and have also resulted in decreased engine efficiency, thereby adding to the expense of operating the engine. The instant invention is concerned with providing an inexpensive'and efficient means of insuring substantially complete burning of the combustible hydrocarbons present in the engine exhaust gases without the necessity of engine component redesign, and without any appreciable loss of engine efficiency.

The device embodying the invention disclosed herein accomplishes substantially complete burning of the engine exhaust gases by providing a profusion of surfaces against which the exhaust gases impinge during their passage through the engine exhaust manifold, these surfaces being heated to incandescence by the exhaust gases themselves, and being arranged in a random array so that the gases must follow a tortuous path, thereby insuring that all of the unburned hydrocarbons in the exhaust gases will impinge against the incandescent surfaces to be burned before discharge to the atmosphere.

This substantially complete burning of the hydrocarbons is accomplished by providing at least one brushlike member in the path of the exhaust gases passing through the engine exhaust manifold, the bristles of the member extending transversely of the direction of exhaust gas flow to provide a profusion of impingement surfaces and interstices therebetween through which the gases are caused to flow in a tortuous path. The bristles are preferably made of a relatively fine, high heat retentive, corrosion resistant wire, such as stainless steel, and are supported in such fashion that they do not contact the remaining structural parts of the structure, thereby obviating heat transfer therebetween so that the wires are maintained at a combustion supporting temperature during engine operation. The multitude of bristles provide a profusion of surfaces against which the hot gases emanating from the engine impinge, and a profusion of interstices among the bristles through which the gases are directed in a tortuous path, the bristles quickly reaching incandescence whereby the gases impinging thereagainst are burned within the exhaust manifold before being passed into the atmosphere.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top plan view of an internal combustion engine exhaust manifold schemmatically showing a device embodying the invention disposed therein;

FIG. 2 is a side elevation on an enlarged scale of the manifold in FIG. 1 with parts broken away and showing a longitudinal cross section through the device embodying the invention disposed within the manifold;

FIG. 3 and FIG. 4 are cross sections taken along lines 3-3 and 44 respectively of FIG. 2, each view being rotated clockwise out of position;

DESCRIPTION OF PREFERRED EMBODIMENT 1 the exhaust system, i.e., the exhaust pipe, muffler, etc.

Generally speaking, the number of entrance ports 22 corresponds to the number of engine cylinders, thus the manifold shown could be utilized with a fourcylinder engine, or two such manifolds could be used with a conventional V-8 engine. It will be obvious that manifolds having varying numbers of entrance ports 22 may be utilized with engines having different numbers of cylinders.

As shown in FIGS. 3 and 4, the manifold may be of a generally oval cross section, with each entrance port formed of a generally cylindrical tube 22 extending through an aperture in the manifold wall and projecting anappreciable distance within the manifold. Suitable collars such as are shown at 26 and 28 may be provided for securing the entrance port within the manifold, and the latter is closed at opposite ends by end plates 30 as indicated in FIGS. 1 and 2. It is to be understood that the oval manifold 20 need not be of one-piece construction as shown, as it could be made in two arcuately shaped pieces which are thereafter secured together by welding or in any other convenient fashion.

Disposed within the manifold 20 in substantially coaxial alignment therein is a tubular member 32 having opposite open ends 34 and 36 terminating spaced from the end walls 30 of the manifold. The tube 32 is provided with apertures 38 aligned with the entrance ports 22, the latter projecting through the apertures and interiorly of the tube, and the tube may be supported within the manifold 20 by being welded to the entrance port sleeves 22, as shown at 40 in FIG. 3. With the arrangement shown, exhaust gases from the engine flow out of the engine cylinder port through sleeves 22 and into the tubular member 32 suspended within the manifold 20. v

Disposed within the tubular member 32 are a pair of exhaust gas burning members 42 and 44, the two being of substantially identical construction, so that a description of one will suffice for both. Referring to the member 42, such is essentially a brush-like structure having a central core 46 and a plurality of sets of bristle-like members 48, 50 and 52, one set for each engine cylinder. The central core or axis of the brush-like member 42 is made of a plurality of strands of cylindrical wire twisted together in helical fashion to form a fairly rigid support for the bristle sets shown at 48, 50 and 52.

Each set of bristles comprises a plurality of individual wire members which project generally radially from the core 46, being secured thereto by gripping engagement between adjacent turns of the wires forming the core. Each set of bristles is disposed in confronting relationship withthe outlet of one of the sleeves 22, as shown in FIG. 2, and extends beyond the sleeve on opposite sides thereof. The wire comprising the core 46 may be wire having approximately 0.090 inch diameter, while the wire forming the bristles may be 'made of a 0.020 inch diameter wire. The wires for both the core and the bristles are of a high heat retentive, corrosion resistant material, such as No. T-3l0 stainless steel or the like. The bristle wires are sufficiently thin so that they are heated to incandescence by the combustion gases, and retain their incandescence throughout the period of operation of the engine. It is important that the material of which the bristles are made be of such a character as to be maintained at a combustion supporting temperature of the exhaust gases, so that the unburned hydrocarbons passing out of the engine and impinging against the bristles are substantially completely burned before being exhausted through the port 24.

As can be seen from an examination of the drawings, upon each exhaust stroke of a respective engine piston, exhaust gases containing unburned hydrocarbons are forced out of the engine cylinder through a port and thence through corresponding entrance port sleeve 22, and are directed into a set of the bristles 48, 50 or 52. Because of the profusion of bristles in each set, these exhaust gases impinge against the bristles and flow around and among the many interstices between the bristles in a tortuous path, thereby impinging the unburned hydrocarbons against the bristle members, which have become incandescent, so that the hydrocarbons are substantially completely burned. Each set of bristles is suitably arranged so that the exhaust gases entering the manifold through any one of the ports 22 must pass through the bristles and thence out through one of the open ends 34 and 36 of the tube 32 before being exhausted through the port 24 to the atmosphere.

In order to minimize heat transfer and thereby maintain the bristles at a temperature sufficient for combustion of the hydrocarbons, the ends of the bristles are maintained spaced from the inner walls of the tube 32, and to achieve this there are provided along the length of the core 46 transversely extending supports 60, which may be in the form of relatively stiff wires securedto the core member 46 and abutting against the inner wall of the tube 32. Three such support structures are indicated in FIG. I for each of the members 42 and 44, and it will be readily understood by those skilled in the art that the number of supports required will be dependent upon the length of the brush-like members 42 and 44. In addition to the support 60, the members 42 and 44 are maintained in the desired spaced-apart relationship within the tube 32 by spacer rods 62 and 64 extending between the core members 46 adjacent opposite ends thereof and secured thereto as by welding or the like.

In order to insure complete combustion, it may be necessary to provide additional combustion air to the exhaust gases, and for this purpose a suitable pump (not shown) may be provided to supply ambient air under pressure to be mixed with the exhaust gases up stream of the tubular member 32. The air pump may be suitably driven by the engine, and is coupled to each of the entrance port sleeves 22 by suitable lines 66 tenninating in venturi jets 68 which direct the air under pressure into the sleeves for mixture with the gases before they reach the burning members 42 and 44.

What is claimed is:

1. Apparatus for burning engine exhaust gases in an internal combustion engine, comprising an exhaust manifold communicatively coupled to said engine for transmitting exhaust gases from the engine and having an outlet for said gases, an elongate tubular member within said manifold open at opposite ends and having inlets for said engine exhaust gases, gas burning means disposed within said tubular member including a multitude of thin, high heat retentive, corrosion resistant members extending throughout and substantially completely across the cross section of said tubular member, said members being positioned in random orientation to provide a profusion of interstices therebetween through which the exhaust gases are directed in a tortuous path, and means for supporting said gas burning means within said tubular member with said thin members out of contact with the walls thereof.

2. Apparatus as defined in claim 1 wherein said gas burning means comprises a profusion of bristle-like thin wire members supported upon a central core and extending generally radially outwardly therefrom, with their distal ends spaced closely adjacent the tubular member.

3. Apparatus as defined in claim 2 wherein said means for supporting said gas burning means comprises at least one relatively rigid member connected to said core and extending into engagement with the inner surface of said tubular member.

4. Apparatus as defined in claim 3 wherein said gas burning means comprises a brush-like member comprising a helically twisted, relatively heavy core wire extending completely through said tubular member, a profusion of relatively fine, bristle-like wires secured to the core wire and extending generally radially outwardly therefrom with their distal ends in close proximity with the inner wall surface of said tubular member, and a plurality of relatively rigid support wires connected to said core wire and extending into abutment with said tubular member inner wall surface.

5. Apparatus as defined in claim 4 wherein said gas burning means includes at least two of said brush-like members extending within said tube in substantially parallel relation.

6. In an internal combustion engine having at least one exhaust port through which the combustion gases are discharged from the engine, and an elongate exhaust manifold coupled to said exhaust port and having an outlet intermediate its opposite ends, combustion gas burning means comprising a sheet-like tubular member supported in space-apart relation within said manifold having open ends spaced from the ends of the manifold, combustion gas inlet communicating with said engine exhaust port, and a pair of gas burning members within said tubular member in the path of combustion gases flowing therethrough, each said gas burning member being of brush-like configuration including an axially-extending core and a multitude of bristle-like, high heat retentive, corrosion resistant, relatively fine wires connected to the core along its length and projecting generally radially from the core in a random, spaced-apart orientation to provide a profusion of impingement surfaces against which the gases impinge and interstices therebetween through which the gases pass in a tortuous path, and means for supporting each brush-like member within the tubular member with the distal ends of said bristle-like wires disposed in closely 3,824,791 I 6 spaced proximity with the walls of said tubular mempressure into said combustion gases at a point intermeber. diate said engine exhaust port and said tubular mem- 7. The invention as defined in claim 6 characterized bet. in that means are provided for introducing air under 

1. Apparatus for burning engine exhaust gases in an internal combustion engine, comprising an exhaust manifold communicatively coupled to said engine for transmitting exhaust gases from the engine and having an outlet for said gases, an elongate tubular member within said manifold open at opposite ends and having inlets for said engine exhaust gases, gas burning means disposed within said tubular member including a multitude of thin, high heat retentive, corrosion resistant members extending throughout and substaNtially completely across the cross section of said tubular member, said members being positioned in random orientation to provide a profusion of interstices therebetween through which the exhaust gases are directed in a tortuous path, and means for supporting said gas burning means within said tubular member with said thin members out of contact with the walls thereof.
 2. Apparatus as defined in claim 1 wherein said gas burning means comprises a profusion of bristle-like thin wire members supported upon a central core and extending generally radially outwardly therefrom, with their distal ends spaced closely adjacent the tubular member.
 3. Apparatus as defined in claim 2 wherein said means for supporting said gas burning means comprises at least one relatively rigid member connected to said core and extending into engagement with the inner surface of said tubular member.
 4. Apparatus as defined in claim 3 wherein said gas burning means comprises a brush-like member comprising a helically twisted, relatively heavy core wire extending completely through said tubular member, a profusion of relatively fine, bristle-like wires secured to the core wire and extending generally radially outwardly therefrom with their distal ends in close proximity with the inner wall surface of said tubular member, and a plurality of relatively rigid support wires connected to said core wire and extending into abutment with said tubular member inner wall surface.
 5. Apparatus as defined in claim 4 wherein said gas burning means includes at least two of said brush-like members extending within said tube in substantially parallel relation.
 6. In an internal combustion engine having at least one exhaust port through which the combustion gases are discharged from the engine, and an elongate exhaust manifold coupled to said exhaust port and having an outlet intermediate its opposite ends, combustion gas burning means comprising a sheet-like tubular member supported in space-apart relation within said manifold having open ends spaced from the ends of the manifold, combustion gas inlet communicating with said engine exhaust port, and a pair of gas burning members within said tubular member in the path of combustion gases flowing therethrough, each said gas burning member being of brush-like configuration including an axially-extending core and a multitude of bristle-like, high heat retentive, corrosion resistant, relatively fine wires connected to the core along its length and projecting generally radially from the core in a random, spaced-apart orientation to provide a profusion of impingement surfaces against which the gases impinge and interstices therebetween through which the gases pass in a tortuous path, and means for supporting each brush-like member within the tubular member with the distal ends of said bristle-like wires disposed in closely spaced proximity with the walls of said tubular member.
 7. The invention as defined in claim 6 characterized in that means are provided for introducing air under pressure into said combustion gases at a point intermediate said engine exhaust port and said tubular member. 